限制驅導式排程與管理技術於TFT-LCD Array製程之應用

Abstract

製造業常面臨訂單達交狀況不佳、在製品數量過多、機台與產品異常頻繁等問題，往往歸咎於生產製程複雜與異常狀況頻繁，以此結論出的行動方案為要求機台與製程穩定度。但限制驅導式排程與管理技術提供管理異常運作模式，透過三個步驟（1）確認系統的限制 （2）充分利用系統限制（3）全力配合步驟二的決策，以追求最大有效產出及降低在製品數量，用管理手法管理異常帶來的影響，達到平穩的生產。

本研究以我國一家生產液晶面板公司中專司中小尺寸面板廠Array 製程為例，於2004年七月起嘗試推動限制驅導式排程與管理技術，為落實生產排程三個步驟，本例實務上分成七個作業（1）出貨計畫（2）參數設定（3）瓶頸排程（4）投片計畫（5）瓶頸派工（6）非瓶頸派工（7）緩衝管理。實證出限制驅導式排程與管理技術能提高達交率、達成最大有效產出及降低在製品數量，並化解追求機台稼動率與訂單達成的衝突，讓生產運作步調漸趨一致。

Manufacturing Companies often face some problems , such as low orders’ hit ratio , too many Works-In- Process (WIP) , high machine down times and quality issues . They always think problems from the complexity of manufacturing processes and frequent abnormal events. Coming out the action items are to stable the machines’ running and products’ quality . But Drum-Buffer-Rope (DBR) provide another way to manage abnormal events , by three steps （1）Identify the system’s constraint（2）Decide how to Exploit the system’s constraint（3） Subordinate everything else to the above decision . Reaching max throughput and min WIP , managing the effect of abnormal events , and smoothly manufacturing. The research is an application of one array fab of a TFT-LCD company in our country , manufacturing below 17 inches’ panels . In July 2004 they try to direct the solution of DBR . In practice they transfer the three steps of DBR to seven operations（1）Decide the shipping plan（2）Setup system parameters（3）Decide the bottleneck plan（4）Form the input plan（5）The dispatching in the bottleneck（6）The dispatching in none-bottleneck （7）Buffer management . By the practice the result shows that DBR could reach higher orders’ hit ratio , higher throughput and lower WIP . And it solves the conflict of keeping machine efficiency and hitting the orders . Let the operations in the manufacturing more consistent .